One of the main problems of modern electric vehicles remains the thickness of the traction battery. It is the battery pack that often forces engineers to raise the floor of the body, increase the roof height, and sacrifice passenger seating to accommodate power elements. CATL announced that it has found a solution to this problem.
The Chinese company has received a patent for a new battery cell design that allows reducing the vertical dimensions of the battery pack without losing functionality and safety. The development is primarily aimed at sports sedans and other low-profile cars, where every millimeter of height matters.
The key change concerns the internal layout of the power element. Engineers have created a special zone of reduced thickness under the battery cell cover. Thanks to this, current-carrying connections inside the battery can be placed more compactly, preventing contact with the metal casing.
According to the developers, this scheme simultaneously solves two problems. Firstly, it allows reducing the height of the battery module. Secondly, it further increases safety by reducing the risk of internal short circuits during vibrations and shock loads.
For electric vehicle manufacturers, this opens up interesting opportunities. A thinner battery pack allows creating cars with a lower seating position, improved aerodynamics, and sporty proportions without compromising interior space.
The development comes amid CATL's massive investments in research and development. In 2025, the company allocated about 22.1 billion yuan (243 billion rubles) to scientific and technical projects.
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